Removing and installing left coolant pipe: VW Touareg I (BAR, BKS, BMK, BUN, …)

🧭 Before you start

Fits: VW Touareg I (7L, 2002–2010)

• Opens: coolant, power steering fluid
• Renewed: o-rings

Don't miss

• (Item 1) and (item 3) should be disregarded.
• Shown from rear with engine removed for illustration purposes.Bolts (3) and (4) only on vehicles with aluminium intake manifold.
• Shown from rear with engine removed for illustration purposes.
• Lay a cloth under the separating point to catch any escaping hydraulic fluid.
• Renew O-rings.Secure all hose connections with the correct type of hose clips (same as original equipment) EKTA (Electronic Parts Catalogue).

🔧 Engine codes this applies to

📋 Procedure

1. Drain coolant .
2. If fitted, pull off rear engine cover (arrows).
3. If fitted, pull off front engine cover (arrows).
4. Disconnect electrical connector (2) on air mass meter 2G246.
5. Remove left air intake hose (1) from air intake pipe.

6. Release retaining clips (3) and remove upper part of air filter housing.
7. Pull connector off air mass meter G70(1).
8. Loosen hose clips (2) and remove right air intake hose (3).
9. Disconnect vacuum hose (arrow) leading to activated charcoal filter system solenoid valve 1N80 by pressing release tab.
10. Move vacuum hose clear. [Note: (Item 1) and (item 3) should be disregarded.]
11. Disconnect electrical connector (2) at activated charcoal filter solenoid valve 1N80.
12. Pull activated charcoal filter system solenoid valve 1N80(item 1) off retainer and move clear.
13. Remove air pipe .
14. Loosen hose clip (1) and remove bolts (3).
15. Remove air pipe out to right.
16. Remove crankcase breather hose (2).
17. Remove bolts (3 … 5) and remove crankcase breather pressure regulating valve.
18. Remove oil drain hose (1). [Note: Shown from rear with engine removed for illustration purposes.Bolts (3) and (4) only on vehicles with aluminium intake manifold.]
19. Remove crankcase breather hoses (1) and (3) together with coolant line (2). [Note: Shown from rear with engine removed for illustration purposes.]
20. Disconnect vacuum hose (arrow) from intake manifold.
21. Separate electrical connection (1) from throttle valve module J338.
22. Remove bolts (arrows) and remove throttle valve module J338. [Note: Shown from rear with engine removed for illustration purposes.]
23. Remove electrical connectors (1) and (4) from retainers and disconnect them.
24. Remove nuts (2) and (3).
25. Remove engine wiring harness bracket from coolant pipe and move it to rear. [Note: Shown from rear with engine removed for illustration purposes.]
26. Extract power-assisted steering system hydraulic oil from reservoir using used oil collection and extraction unitV.A.G 1782. [Note: Lay a cloth under the separating point to catch any escaping hydraulic fluid.]
27. Disconnect hose (arrow) from power-assisted steering fluid reservoir. [Note: Lay a cloth under the separating point to catch any escaping hydraulic fluid.]
28. Remove bolts (1) and nut (2) and remove supply pipe for power-assisted steering.
29. Remove bolt (1) and lift oil dipstick guide tube out upwards (arrow).
30. Remove coolant hose (arrows).
31. Disconnect electrical connector (arrow) on Hall sender 4G301.
32. Unscrew bolts (1) and (2).
33. Disconnect left coolant pipe from coolant hoses (arrows). [Note: Renew O-rings.Secure all hose connections with the correct type of hose clips (same as original equipment) EKTA (Electronic Parts Catalogue).]
34. Renew O-ring for dipstick guide tube and insert guide tube into hole in upper part of sump
35. Fill power-assisted steering reservoir with hydraulic oil and bleed system 48.
36. Fill with coolant .

Other VW procedures

• Renewing valve stem oil seals with cylinder head removed
• Removing and installing coolant pipe (left-side) – Audi Q7
• Valve gear - exploded view · 4 torque figures
• Removing and installing engine mountings – Audi A8 D4
• Removing and installing intake manifold – VW Touareg I
• Removing engine · 41 torque figures
• Removing and installing camshaft – VW Golf Cabriolet · 47 torque figures
• Adjusting valve timing – VW Passat B5 · 83 torque figures
• Removing and installing camshafts – VW Passat B6 · 39 torque figures
• Removing and installing coolant pump · 53 torque figures